ii

AADCO 737-11 AND 737-12 PURE AIR GENERATORS

TABLE OF CONTENTS

Section Page

LIST OF ILLUSTRATIONS .................................................................................... iii

0.0 DAMAGED AND/OR LOSS IN SHIPMENT PROCEDURE ..................................... 1

1.0 INSTALLATION ...................................................................................................... 2

2.0 REAR PANEL CONNECTIONS .............................................................................. 4

3.0 OPERATIONAL TEST ............................................................................................ 5

4.0 OPERATIONAL PROCEDURES ............................................................................ 7

5.0 PRINCIPLE OF OPERATION ............................................................................... 10

6.0 BALLAST TANK AND BALLAST BLEED SYSTEM .............................................. 12

7.0 COMPRESSOR UNIT .......................................................................................... 15

8.0 COMPRESSOR CONTROL SYSTEM .................................................................. 16

9.0 PURIFICATION REACTORS ................................................................................ 18

10.0 METHANE REACTORS ....................................................................................... 20

11.0 PERFORMANCE SPECIFICATIONS ................................................................... 22

12.0 PREVENTIVE MAINTENANCE ............................................................................ 24

13.0 TROUBLE SHOOTING ......................................................................................... 25

14.0 PRESSURE SWITCH ADJUSTMENT .................................................................. 36

15.0 COMPONENT REPLACEMENT ........................................................................... 38

16.0 PARTS LIST ......................................................................................................... 40

ILLUSTRATIONS ............................................................................... 42 through 65

WARRANTY ......................................................................................................... 66

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AADCO 737-11 AND 737-12 PURE AIR GENERATORS

LIST OF ILLUSTRATIONS

Figure Page

1 GENERATOR AND SILENCER HOUSING, REAR VIEW .................................... 42

2 GENERATOR W/MIXER-RECEIVERS & “HOUSE AIR ADAPTOR ...................... 43

3 GENERATOR WITH MANUAL BALLAST BLEED & NO COMPRESSOR ............ 44

4 FRONT PANEL, GENERATOR WITH AUTO BALLAST BLEED .......................... 45

5 GENERATOR UNIT, REAR PANEL ..................................................................... 46

6 GENERATOR UNIT, INTERNAL VIEW, .............................................................. 47

7 GENERATOR, “HOUSE” AIR CONFIGURATION ................................................ 48

8 GENERATOR, BALLAST TANK REMOVED ........................................................ 49

8a GENERATOR, BALLAST TANK REMOVED, LEFT SIDE .................................... 50

9 BALLAST TANK WITH MANUAL BLEED ............................................................. 51

10 COMPRESSOR SILENCER HOUSING, REAR PANEL ....................................... 52

11 COMPRESSOR, INTERNAL VIEW ...................................................................... 53

11a COMPRESSOR ASSEMBLY, EXPLODED VIEW ................................................ 54

12 GC ANALYSIS FOR C02, “C” PURIFICATION REACTOR ................................... 55

13 CO2 OUTPUT FROM “A” VS. “C” PURIFICATION REACTOR ............................. 56

14 MOISTURE VS TIME NOMOGRAPHS ................................................................ 57

15 FID RESPONSE CYLINDER AIR VS “B” PURIFICATION REACTOR .................. 58

16 EFFICIENCY OF THE METHANE REACTOR ...................................................... 59

17 PNEUMATIC DIAGRAM ....................................................................................... 60

18 WIRING DIAGRAM .............................................................................................. 61

19 AUTO BALLAST BLEED ...................................................................................... 62

20 REMOTE COMPRESSOR OPERATION & AUTO BALLAST BLEED ................... 63

21 737-11 ROTAMETER FLOW NOMOGRAPH ....................................................... 64

22 737-12 ROTAMETER FLOW NOMOGRAPH ....................................................... 65

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0.0 DAMAGED AND/OR LOST IN SHIPMENT PROCEDURE

0.1 SHIPMENTS FOB FACTORY. This shipment was thoroughly inspected before

it was delivered to the carrier. Our responsibility for this shipment has now ended. Therefore, a thorough inspection of the contents should be made upon its arrival.

0.2 In the event any portion of the shipment is damaged or missing, do not sign the

bill of lading or express receipt until the freight or express agent makes appropriate notation on the receipt.

0.3 Concealed damage means damage that may not be apparent until after the

items are unpacked and tested. In case of concealed damage, A written request for inspection should be filed with the carrier within 15 days of the delivery date. Delay in making this request may provide grounds for refusal of your claim. Be certain to retain the carbon, packing materials, wrappings, etc., until the carrier has made his inspection. Keep in mind that concealed damage can occur from rough handling though the cartons show no evidence of external damage.

0.4 The carrier may request return of the damaged item to us for inspection and

repair. In this event, we will repair or replace the item and invoice you for the costs involved. This invoice then becomes part of your claim upon the carrier.

0.5 SHIPMENTS FOB DESTINATION. In case of damage in transit on shipments

made FOB Destination, we will gladly handle filing of the claim, provided an acceptable inspection report from the carrier is furnished to us. If our claim is disallowed because of your negligence in obtaining the report, billing you for the repair or replacement charges will be necessary.

0.6 RETURN TO ADDCO INSTRUMENTS, INC. If your property, while being

returned to AADCO Instruments, Inc., is damaged in transit, it will be your responsibility to file a claim with the carrier. To assist you we will secure an inspection report from the carrier and forward it to you.

0.7 Prior to shipment to AADCO Instruments, Inc. you should call or write notifying

us of your intent. You must include some identifying note or letter with the item. This note should include the name of your factory contact and the nature of the damage.

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1.0 INSTALLATION 1.1 Before attempting installation, it should be borne in mind that the performance

of the pure air generator hinges upon the availability of a large volume of pressurized air in close proximity to the instrument. THIS IS MANDATORY. If the air source in unable to satisfy the sudden demands for pressurized air, the pure air generator will not perform to specifications.

1.2 AADCO Instruments supplies pure air generators with or without air

compressor, depending upon availability of compressed air at the user’s site. If “plant” air is available, follow the procedure outlined for INSTALLATION WITHOUT COMPRESSOR (Section 1.6), otherwise use the INSTALLATION WITH COMPRESSOR (Section 1.9) procedure.

1.3 If initial visual inspection reveals no damage after unpacking, remove all

shipping plugs from the bulkhead fittings on the rear of the instrument(s) and remove the instrument cover. Should there be any indications of damage, see Section 0.0 for instructions. If further information is required, consult the factory.

1.4 Locate the unit in an area that will permit a free flow of air, avoiding confined

spaces. This is especially important if the unit houses a methane reactor system. The heat generated during operation of the methane reactor must be dissipated away from the instrument. If the unit does not contain a methane reactor, location is not critical. However, it should be kept away from the wall.

1.5 It is not unusual to situate these instruments on specially constructed shelves

above head level, in out-of-the-way places outside the area of use; e.g., in hallways, electrical rooms, etc.

1.6 For INSTALLATION WITHOUT COMPRESSOR, using a “plant” or “house” air

source, locate the unit as in Section 1.4. Install the “house” air adapter, Figure 2 (54), being certain that the connection to the PUMP fitting, Figure 2 (33), is tight. Connect the air supply to the inlet fitting of the “house” air adapter, Figure 2 (56). Close the water drain valve, Figure 2 (55), finger tight.

NOTE: INLET AIR PRESSURE CANNOT EXCEED 100-PSIG NOR BE LESS

THAN 70-PSIG. 1.7 Install the power cord supplied into the power inlet, Figure 2 (29), and then into

a suitable electrical outlet. 1.8 Admit the source air into the “house” air adapter. The INPUT PRESSURE

gauge, Figure 3 (3), should indicate the pressure of the air source. Leak check all incoming air connections with soap solution and remedy as needed. The unit is ready for operation.

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1.9 For INSTALLATION WITH COMPRESSOR, place the compressor assembly between two level surfaces so that the underside of the assembly is exposed. DO NOT INVERT. Remove the two red shipping bolts located on the underside and hold for future use.

1.10 Place the generator unit and compressor unit side-by-side as shown in Figure

1. Install the in-line filter, Figure 1 (50), taking care that the directional arrow on the filter points away from the compressor unit and toward the generator unit.

1.11 Connect all power cords supplied, as shown in Figure 1. Once the six-foot

power cord has been inserted into the proper electrical outlet, the unit is ready for operation.

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2.0 REAR PANEL CONNECTIONS. 2.1 The DUMP bulkhead connection, Figure 5 (32), is the outlet for air containing

those impurities removed from the unclean feed air. It is vented outside the instrument cabinet to prevent deposition of water and other materials within the instrument. The DUMP connection also provides a suitable connection for sample collection of the impurity concentrate which elutes from this port.

2.2 The DUMP port must NOT be closed or impeded by any restriction that would

produce back pressure at this point. 2.3 To eliminate the “hissing” noise associated with the purification/purge cycle, a

short length of large bore ¼-inch o.d. plastic tubing, which is supplied, should be connected between the DUMP fitting, Figure 2 (32), on the pure air generator unit and the DUMP fitting, Figure 10 (38), on the compressor unit (see Figure 1). This length of tubing now causes the purge flow to exit within the compressor silencer housing and become inaudible.

2.4 The PUMP bulkhead fitting Figure 5 (33) and Figure 10 (37), are large bore AN

connections to accommodate the swivel connectors of the braided metal covered, Teflon tubing carrying air from the compressor. Care should be taken that this tubing is kink-free as in Figure 1.

2.5 The PURE AIR bulkhead connector, Figure 5 (34), is the pure air outlet from

the pure air generator. It will accept ¼-inch swage type connectors.

NOTE: Particulate filters are neither required nor recommended. 2.6 The female power connector, Figure 5 (29), receives the main power cord that

supplies power to the full AADCO pure air generator system. It is a three-prone twist connector. When connection is made, the male connector should be rotated clockwise to prevent the cable from disengaging during operation.

2.7 The AUXILIARY POWER outlet, Figure 5 (30), provides power to the

compressor through either the PUMP switch, Figure 4 (1), or, if present, the remote DC jacks, on the rear of the generator unit.

2.8 Those units supplied for connection to “house” air are shipped without PUMP

switch, fuseholder, and AUXILIARY POWER outlet. The AN PUMP connector is replaced with a 3/8-inch swage connector as in Figure 2 (33).

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3.0 OPERATIONAL TEST. 3.1 DO NOT CONNECT ANY EQUIPMENT TO THE PURE AIR GENERATOR

SYSTEM AT THIS TIME. 3.2 After making all electrical and pneumatic connections to both generator and

compressor units according to instructions attached to each unit and as shown in Figures 1 and 2, the system is ready for operation. DO NOT MAKE ANY REMOTE CONNECTIONS AT THIS TIME; e.g., autocalibrator output, external timer, etc.

3.3 IF INSTALLATION HAS BEEN COMPLETED AS SHOWN IN FIGURE 1

WHEREBY THE PURE AIR GENERATOR USES AN AADCO INSTRUMENTS SUPPLIED COMPRESSOR, REFERENCE FIGURE 4 FOR THE FOLLOWING OPERATIONS.

3.4 Depress the PUMP switch (1) on the generator unit by depressing the lamp

itself. The compressor should start and the indicator lamp within the PUMP switch should light. Within a short time there should be indication of increasing input pressure as noted on the INPUT PRESSURE gauge (3).

NOTE: The compressor will not start at this time if any pressure greater than

60-psig appears on the INPUT PRESSURE gauge. 3.5 At this time, the hoses leading from the compressor unit to the generator unit

should be checked for leaks by applying a soap solution to all of the connections and tightening as required.

3.6 When the input pressure reaches 80-psig as evidenced on the INPUT

PRESSURE gauge, the compressor will cease to operate. The input pressure at this time will remain constant at 80-psig.

NOTE: Checking for leaks when the compressor is not operating will be

pointless since the connecting hoses between the compressor and generator will not be pressurized. This check can be made only when the compressor is running.

3.7 Depress the power switch (2) by depressing the lamp itself. The indicator lamp

within the switch will light. The METHANE HEAT lamp (4) will light if there is a methane reactor within the unit. There should be an audible “click” of the solenoid valve on the purification reactor followed immediately by a momentary decrease of the input pressure. This is the initial pressurization of one side of the purification reactor. There may also be a rise in the output pressure, as evidenced on the OUTPUT PRESSURE gauge (6), if the OUTPUT PRESSURE REGULATOR (5) had been set previously to some pressure. In addition, the cooling fan on the inside rear wall of the generator should operate, Figures 6 and 7 (28).

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3.8 Wait at least one minute to allow both sides of the purification reactor to pressure up and then adjust the output pressure to any desired pressure up to 50-psig with the OUTPUT PRESSURE REGULATOR. This output pressure will be observed on the OUTPUT PRESSURE gauge (6).

3.9 Output flow should be adjusted via the OUTPUT FLOW ADJUST valve (13) to

some value between zero and 10.0 on the rotameter (10). 3.10 After about one-half hour of operation the METHANE HEAT lamp (4), if

present, should cycle, indicating that a maximum temperature has been reached and is being maintained. During this half-hour “burn-in”, copious amounts of water will exit from the PURE AIR FITTING, Figure 5 (34), on the rear of the generator unit. It is advantageous to attach temporarily a short (six to twelve-inch by ¼-inch o.d.) length of plastic tubing to that fitting to permit the exiting water to clear the hoses and power cords of the unit.

3.11 The METHANE HEAT pyrometer (7) should indicate 290C ± 10C. If a temperature other than this is observed, refer to Section 13.21, Methane Reactor, for remedial action.

3.12 During the entire interval, from start up to full maximum temperature of the

methane reactor, the input pressure should be cycling between 60 and 80-psig indicating that the pressure switch is operating properly. If not, consult Section 14.0, Pressure Switch Adjustment.

3.13 If all operations have been followed according to Sections 3.3 through 3.12,

allow the system to operate for several hours to permit maximum elimination of the “burn-in” water. See Figure 14 for moisture versus time for both purification and methane reactors.

3.14 IF INSTALLATION HAS BEEN COMPLETED AS SHOWN IN FIGURE 2

WHEREBY THE PURE AIR GENERATOR USES “HOUSE” AIR FOR ITS AIR SOURCE, REFERENCE FIGURE 3 FOR THE FOLLOWING OPERATIONS.

3.15 Admit the source air into the pure air generator. The INPUT PRESSURE

gauge (3) should indicate the pressure of the source air.

NOTE: This pressure MUST NOT BE LESS THAN 70-PSIG NOR GREATER THAN 100-PSIG. If the input pressure is less than 70-psig, the quality of the air produced by the pure air generator will be jeopardized. If the pressure is greater than 100-psig the unit may malfunction since the components are rated for no greater than 100-psig.

3.16 Follow the procedures as outlined in Section 3.7 through Section 3.13.

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4.0 OPERATIONAL PROCEDURES. 4.1 Once all connections and checkouts have been completed as in Sections 3.0,

the pure air generator system is ready for connection to the equipment that is to receive the zero air. Connections must be made with ¼-inch o.d. thin-walled tubing with the using equipment located as close to the pure air generator as possible. One-eighth inch o.d. tubing or small bore ¼-inch tubing should be avoided because of the back pressure exerted on the system by the restrictive tubing.

4.2 If connection fittings at the using equipment are _-inch swage-type, use ¼-inch

large bore tubing from the pure air generator to the using equipment and then reduce to _-inch tubing, keeping the _-inch length as short as possible. All tee’s should be ¼-inch also.

4.3 After completing all plumbing connections, close all needle valves and flow

control devices at the using equipment and open the OUTPUT FLOW ADJUST valve, Figure 4 (13), completely counter clockwise so that there is NO flow at the using equipment. The rotameter ball on the pure air generator should drop to zero indicating that the system is leak tight. If not, check for leaks at all connections with soap solution and tighten all loose connections until the rotameter ball does drop to zero. It is imperative that all leaks are detected and remedied before putting the system into full operation.

4.4 To determine the proper output pressure from the pure air generator,

ascertaining the greatest pressure required by any or all of the instruments is necessary. For example, if there are five instruments and the highest pressure required for any one or all of the instruments is 30-psig, then the output pressure of the pure air generator can be set no lower than 40-psig. This 10-psig pressure differential is mandatory for proper operation of any differential pressure regulator. The 40-psig accommodates not only that instrument with the 30-psig requirement but all of the others as well.

4.5 If the instruments connected to the pure air generator do NOT have their own

pressure regulators but, instead, have a mandated input pressure at which the instruments are to function optimally, then it is the responsibility of the operator to install separate pressure regulators after the generator, in the line, for each instrument. AADCO Instruments, Inc. offers in-line pressure regulators for this purpose (Part No. 20033).

4.6 There are two pressure conditions for operating the pure air generator.

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4.7 The first pressure condition is when the output is permitted to enter an ambient pressure environment; i.e., in which the effluent enters and purges an environmental chamber; or passes into a sampling manifold that itself vents to the atmosphere, etc. In each case there will be no back pressure exerted upon the pure air generator.

4.8 In this “no back pressure” situation, the output flow is controlled by the

OUTPUT FLOW ADJUST knob, Figure 4 (13), and the flow reading is taken from the rotameter, Figure 4 (10), in millimeters and compared with the applicable nomograph, Figure 21 or 22, for actual flow in liters per minute.

4.9 The second pressure condition is when the pure air generator is connected to

external equipment and the OUTPUT FLOW ADJUST valve is opened counter clockwise, permitting full flow through the valve. Flow control in this situation is performed at the external equipment through its flow control system. In this instance, the pure air generator is operating in a “back pressure” mode, placing the rotameter under pressure and no longer allowing the rotameter to be direct reading.

4.10 The pressure under which the rotameter is operating is determined by the

operator when setting the output pressure with the OUTPUT PRESSURE REGULATOR, Figure 4 (5). This pressure setting will greatly influence the relationship between the observed flow on the rotameter and the actual flow.

4.11 The formula for determining actual flow is N+1 x R.

N = Output pressure in atmospheres (14.7 psi = 1 atmosphere).

R = Rotameter reading in LPM (NOT millimeters). 4.12 You can readily see that at 45-psig output pressure the indicated flow at the

rotameter will be exactly one-half the actual flow and you must multiply the rotameter readings at this pressure (45-psig) by TWO to determine the actual flow.

4.13 For the operator’s convenience, listed in Section 4.14 are the multipliers for

each output pressure setting. Simply multiply the rotameter reading in LPM (determined by the proper nomograph, Figure 21 or 22) using the multiplier from the listing for that operating pressure.

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4.14 OUTPUT PRESSURE MULTIPLIER 60 2.24 55 2.16 50 2.08 45 2.00 40 1.91 35 1.82 30 1.73 25 1.63 20 1.53 15 1.415 10 1.29 5 1.155

4.15 The purpose of this exercise is to allow the operator to know his flow conditions

but, more importantly, TO AVOID EXCEEDING THE OUTPUT CAPACITY OF THE PURE AIR GENERATOR AND JEOPARDIZING THE OUTPUT PURITY. Each pure air generator has a maximum output rating and the operator should know this before setting flows.

4.16 Any instrument that is sensitive to even slight variations in oxygen

concentration; i.e., flame ionization detectors used with total hydrocarbon analyzers, gas chromatographs, flame photometric detectors, etc., all require incorporation of mixer-receivers, Figure 2 (60), in the pure air generator system for homogenization of the air mixture before use by the above-mentioned detectors. NDIR, chemiluminescent, photoionization, and electrochemical sensors are unaffected by slight variations in oxygen concentration and, therefore, do not require mixer-receivers. See Section 18, Parts List, for appropriate models.

4.17 SHUTDOWN PROCEDURE. 4.18 If the unit is not to be used for one week or more, depress the PUMP switch,

Figure 4 (1), depress the POWER switch, Figure 4 (2), and immediately cap both the PURE AIR outlet, Figure 5 (34), and the DUMP fitting, Figure 5 (32), to avoid contaminants from entering the system.

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5.0 PRINCIPLE OF OPERATION (REFERENCE FIGURE 17). 5.1 The 737-series pure air generators produce absolutely clean air from

pressurized unclean air by chromatographic techniques. Pressurized air from a compressor or other source enters the number one or number two column system, depending upon the status of the solenoid valve at the inlet of the column. These valves are normally closed so that when the POWER switch is OFF the inlets to the columns are closed, sealing the system against possible contamination.

5.2 The pressurized air passes through the column where selective adsorption

takes place, with a subsequent separation of the various components present in the air. Only the desired components, which elute first, are permitted to reach the end of the column system and elute, whereupon the solenoid valve at the head of the separation column closes and the solenoid valve at the inlet to the alternate column systems opens.

5.3 Pressurized unclean air now enters the alternate column system where

separation again takes place. The alternation of the two column systems produces a steady flow of purified air.

5.4 During the interval that pressurized unclean air is being separated in one

column, a portion of the clean air passes through the purge valve and back flushes the alternate column of impurities. This purge valve, Figures 8 and 8a (19), has been set at the factory for optimum flow and MUST NOT BE ALTERED.

5.5 The back flush flow of air with impurities exits from the instrument through the

swage bulkhead connector labeled DUMP at the rear of the instrument, Figure 5 (32). THIS EXIT MUST NOT BE RESTRICTED. A back pressure situation must be avoided at this fitting.

5.6 The timer, Figure 8 (41), which provides alternate power to the solenoid valves,

is set to effect the proper residence time of the unclean air in the columns and the purge time for each size reactor. THE TIMER MUST NOT BE ALTERED.

5.7 To prolong the life of the support media within the columns, it is mandatory that

the operational directions for the instrument be followed as closely as possible. Selection of this separation media, residence time in the column, proper input pressures, purge flows and column volumes have been determined to meet the requirements of the particular 737-series pure air generator being used. These components are NOT interchangeable except among units of the same rated output.

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5.8 Damage to the purification reactor can occur if: (a) improperly filtered air is admitted to the columns as with oil compressors, (b) water is admitted to columns due to oversight on the operator’s part in failing to drain the ballast tank and allowing water to carry over, or (c) the unit is operated above its rated capacity, or (d) the input pressure requirements are not met. See Section 3.15.

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6.0 BALLAST TANK AND BALLAST BLEED SYSTEM 6.1 The ballast tank is placed in the system after the compressor, prior to and in

close proximity to the purification reactor, to serve as a reservoir for the pressurized input air. Each tank has been carefully sized for the rated capacity of its pure air generator.

6.2 When the solenoid valve at the inlet to the column opens, a requirement for a

rapid supply of pressurized air develops. The compressor alone would be unable to satisfy this requirement within a reasonable amount of time and would cause great variations in the input pressure and improper separations within the purification reactor, resulting in variations in output pressure and flow and also a deterioration in purity. The pressurized volume within the ballast tank, located immediately adjacent to the columns, provides an instant response to this need.

6.3 Because the ballast tank is so critical to the operation of the system, care must

be taken to ensure there will be no decrease in its volume. Volume loss occurs only when water from the input compressed air is permitted to collect in the tank.

6.4 AADCO Instruments, Inc. supplies an internally-coated, rustproof ballast tank

with each system and offers three options for bleeding the coalesced water from the tank. These are: (a) Manual Toggle Valve System, (b) 737-106/107 Auto Ballast Bleed, and (c) 737-108 Independent Automatic Ballast Bleed.

6.5 The MANUAL TOGGLE VALVE SYSTEM is a simple toggle valve, Figure 3

(12), on the front panel of the generator unit. This valve should be opened at least once every three days while the system is operating and the ballast tank is pressurized. The air pressure within the tank forces the accumulated water through a bevel-cut tube, situated on the bottom of the tank, to the toggle BALLAST BLEED valve and then to the BALLAST BLEED port, Figure 3 (11). During periods of high humidity, a once per day bleed would be required. The Manual Toggle Valve System is standard unless automatic options are requested.

6.6 The 737-106 REMOTE COMPRESSOR OPERATION finds use where there is

a need for a noncontinuous supply of zero air usually for calibration purposes, for short intervals and at inconvenient times. Typical application would be zero calibration of many instruments, at a remote site, at midnight when zero air would be needed for only an hour. See Section 13.27 for service information.

6.7 In practice, the generator unit would be in full operation but with the PUMP

switch OFF. The POWER switch would be ON supplying power to the methane reactor and timer. All portions of the system are operating except the compressor.

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6.8 An external programmer applies 3-33V DC to the remote jacks, Figure 5 (31). This external DC voltage source is applied to the coil of the DC relay, which in turn, applies power to the electrical pressure switch, Figures 6 and 9 (17). Since the pressure within the ballast tank will be less than 60-psi at this time, the switch will be closed and, therefore, power will be applied to the coil of the AC solid state relay and, consequently, to the compressor itself. Though the PUMP switch is OFF, the PUMP indicator lamp will light when the external DC voltage is applied to the remote jacks, signaling that the compressor assembly is in operation, including power to the cooling fans, Figure 11 (45), within the silencer housing. At this time the ballast tank will fill and the entire system will be operational within ten minutes.

6.9 The 737-107 AUTO BALLAST BLEED becomes a necessary option when

there is unattended/remote operation of the system, as with the 737-106 Remote Compressor Operation. It is mandatory that the internal volume of the ballast tank not lessen through water accumulation. Because of this, a reliable automatic ballast bleed system must be incorporated. The two solid state timers, T-1 and T-2, Figure 8 (25 and 26), and solenoid valve, Figure 9 (35), make up this automatic bleed system. When the PUMP switch is depressed or DC voltage is applied to the remote jacks, power is applied to the compressor and, simultaneously, to timers T-1 and T-2.

6.10 The moment the PUMP switch is depressed or DC voltage is applied to the

remote jacks, the operator should begin monitoring the BALLAST BLEED port, Figure 4 (11). In about ten minutes the auto-ballast bleed solenoid valve, located on the ballast tank, Figure 9 (35), within the generator unit, should open and remain open for thirty to forty-five seconds. Evidence of this will be a discharge of air and possibly water, if present, from the BALLAST BLEED port.

6.11 It is necessary to attach a collection container to the BALLAST BLEED port

Figure 4 (11), with _-inch o.d. tubing to capture the discharged water. A pressure relief hole must be cut into the top of the container to permit the air to escape and trap only the water. IT IS IMPERATIVE THAT CONNECTING THE DC VOLTAGE TO THE REMOTE JACKS BE MADE WITH POWER OFF AT THE DC SOURCE AND THAT POLARITY BE STRICTLY OBSERVED.

6.12 The operator is manually able to determine the condition of the ballast tank

anytime by depressing the momentary contact switch, Figure 4 (12), on the front panel of the generator unit.

6.13 The 737-108 INDEPENDENT AUTOMATIC BALLAST BLEED option will

bleed the ballast tank of any accumulated water once every twenty-four hours, for thirty to forty-five seconds.

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6.14 This option is controlled only by the PUMP switch on the front panel of the pure air generator. When this switch is depressed the compressor is activated and, simultaneously, power is applied to this bleed option.

6.15 In operation, when the PUMP switch is depressed, power is applied to the

twenty-four-hour timer motor. As the timer cam rotates, the cam follower tracks the outer diameter of the cam, dropping into the cam detent once every twenty-four hours. During this detent interval power is applied to the adjacent solid state timer and, simultaneously, through the solid state timer to the electrical solenoid valve, Figure 9 (35), on the ballast tank. This valve opens, the accumulated water is forced from the pressurized tank and vented through the BALLAST BLEED port, Figure 4 (11), on the face of the generator.

6.16 For those locations enduring conditions of high humidity, AADCO Instruments

offers twenty-four hour timers with two or four detents. This assures ballast tank bleeding of twice or four times daily. Consult the factory before ordering.

6.17 During the detent interval the manual/electrical BALLAST BLEED switch is

inoperative. This detent interval is for three minutes every twenty-four hours. All other times, exclusive of the detent interval, the operator may manually bleed the ballast tank through use of the BALLAST BLEED switch located next to the BALLAST BLEED port on the face of the instrument.

6.18 Though the detent interval persists for three minutes, the solid state timer will

bleed the ballast tank only thirty to forty-five seconds during this three minute interval.

6.19 Attaching a suitable container to the BALLAST BLEED port to contain the water

forced from the ballast tank during the auto-bleed interval is necessary.

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7.0 COMPRESSOR UNIT. 7.1 A compressor, Figure 11 (43), contained in a separate rack-mounted,

soundproofed assembly, Figures 1 and 11, provides compressed air to the pure air generator. Each compressor is sized for a particular generator system. When replacement is necessary, it should be replaced with the same size compressor with the same voltage requirements.

7.2 The compressor is shock-isolated from the cabinet proper by four springs and a

special mounting plate, Figure 11 (46) and 11a. 7.3 Operating air and cooling air are both admitted at the front bottom of the unit,

passing through a sound baffle system, and into the compressor chamber. Care must be taken to avoid obstructing both the incoming air and the hot air exiting from the cabinet.

7.4 Hot air is removed from the cabinet by two high volume fans, Figure 11 (45),

mounted on vertical ducts within the compressor cabinet. Failure of the fans will cause the compressor to stop operating, though power is applied, because of increased temperature within the compressor chamber. A thermal switch, located within the compressor motor, performs this operation. This switch is both non-adjustable and inaccessible.

7.5 In addition to the two duct-mounted cooling fans, a third fan is attached to the

drive shaft of the compressor itself. This fan is located directly beneath the louvered shroud on the front end of the compressor and is press-fit on the drive shaft.

7.6 Compressor replacement is dictated by its inability to supply compressed air at

the desired rate and/or pressure. See Section 12.5 for diagnostic procedures and Section 13.1 for service.

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8.0 COMPRESSOR CONTROL SYSTEM (SEE FIGURE 17 FOR PNEUMATIC REFERENCE AND FIGURE 18, 19 AND 20 FOR ELECTRICAL REFERENCE.)

8.1 A combination pressure switch/pressure relief valve system is installed in all

AADCO pure air generators with output volumes greater than 1-LPM but less than 50-LPM.

8.2 The purpose of this system is to permit the compressor to operate intermittently

rather than continuously. The compressor will turn ON at 60-psig or less and OFF at 80-psig. Operating the compressor in this manner greatly reduces compressor wear and promotes cooler operation, both of which extend its lifespan.

8.3 During operation the ballast tank, Figures 6, 7 and 9 (16), serves as the

pressure reference for the system. The pressure switch, Figures 9 and 11 (17), serves as the sensor and the check valve, Figures 6 and 9 (24), confines the pressurized air within the ballast tank once the compressor has turned off.

8.4 The pressure switch, Figure 9 and (17), is a normally closed switch, closing at

60-psig or less and opening at 80-psig. This switch controls the coil of the solid state relay, Figure and 8 (21), which in turn supplies power to the compressor through the AUX POWER outlet, Figures 6 and 8 (30).

8.5 Any low pressure condition (60-psig or less) within the ballast tank produces a

closed switch condition at the pressure switch. This in turn causes power to be supplied to the compressor via the solid state relay and AUX POWER outlet.

8.6 At 80-psig the pressure switch opens, removing power from the coil of the solid

state relay, which in turn removes power from the compressor. 8.7 The compressor pressure relief valve, located in the compressor silencer

housing, (a normally closed three-way valve) is wired in parallel with the power to the compressor at the AUX POWER outlet. When power is removed from the compressor, it is also removed from the compressor pressure relief valve. This causes the valve to vent all tubing from the compressor to the valve to atmospheric pressure.

8.8 The compressor pressure relief valve is an important part of the compressor

control system. Its function is to vent to atmospheric pressure all tubing leading from the compressor to the PUMP inlet on the rear of the pure air generator when the compressor is OFF.

8.9 If the compressor is permitted to start against pressure, its starting current

begins to rise dramatically, causing the compressor to run hotter, increasing wear. The compressor pressure relief valve eliminates this problem.

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8.10 The AUX POWER outlet, Figure 5, 6 and 8 (30), is a four-conductor connector, one lead (the red lead) carries power to the cooling fan located within the compressor silencer housing. Power is applied to the cooling fan continuously, whether the compressor in ON or OFF, thus maintaining a favorable temperature within the compressor silencer housing.

8.11 The compressor supplies air via the ballast tank to the pure air generator

through the PUMP fitting, Figure 10 (37), on the rear of the compressor unit. This air enters the generator unit via its PUMP fitting, Figure 5 (33). This air passes through the compressor pressure relief valve, through the check valve, Figures 6 and 9 (24), and into the ballast tank, Figures 6, 7 and 9 (16), where its pressure is monitored by the pressure switch, Figure 9 (17), and the INPUT PRESSURE gauge, Figures 3 and 4 (3).

8.12 At 80-psig the pressure within the ballast tank causes the pressure switch to

open, removing power from the coil of the solid state relay, which in turn removes power from the compressor and the compressor pressure relief valve.

8.13 When power is removed from the compressor, the compressor pressure relief

valve vents the connecting tubing to atmospheric pressure and causes the check valve, Figures 6 and 9 (24), to close, confining the pressurized air within the ballast tank.

8.14 This pressurized air enters the purification reactor, Figures 6, 7 and 8 (18).

During the purification process, the air within the ballast tank is consumed, decreasing the pressure within the tank again to 60-psig. At this point the entire procedure is repeated, producing the ON and OFF operation of the compressor.

8.15 This system will operate efficiently only if some preventive maintenance is

performed every three or four weeks of sustained operation. These procedures are covered in Section 12.0

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9.0 PURIFICATION REACTORS 9.1 AADCO Instruments, Inc. offers four basic types of purification reactors,

designated “A”, “B”, “C”, and “D”. 9.2 The “A” PURIFICATION REACTOR produces air of purity outlined in Section

11.0 and with an oxygen concentration of 20.8% ± 0.3%. In addition, the CO2 concentration will be that of the ambient environment of the user’s locale (~350-ppm). This purification reactor should be specified if the operator wishes to avoid calibration disparities where it is essential that the carbon dioxide level for both the “zero” air and the sample be the same; e.g., use of the flame photometric detector or nondispersive infrared. The “A” model is the most universal purification reactor for air monitoring applications and is usually supplied when advised of this intended use.

9.3 The “B” PURIFICATION REACTOR is factory set to produce air with the same

purity as the “A” model but with an oxygen concentration of 37.0% ± 0.5%, at specified conditions. By in-house experimentation, this concentration has been found to produce a greatly increased response for most commercial flame ionization detectors over that response experienced with cylinder air. This has since been field proven and has become the purification reactor of choice when high sensitivity FID is required. It has also been found to decrease the noise level of the flame photometric detector when used in conjunction in a gas chromatography mode. Use of this purification reactor will eliminate both the oxygen and air cylinders when operating this detector for that application.

9.4 It should be noted that output flows less than 50% of the rated output should be

avoided with any model pure air generator that contains a “B” reactor. This is the lower threshold for maintaining the oxygen output at 37%. Flows below this level will produce an oxygen enrichment greater than 37% oxygen. This higher oxygen level causes the flame to become too hot with a consequent increase in noise. This increased noise can be nullified, without loss of sensitivity, by decreasing the hydrogen flow slightly.

9.5 Those chromatographers actively using flame ionization detectors with pure air

generators having “B” reactors experience a response from three to ten times greater than the response of the same detector with cylinder air, particularly if nitrogen is used as the carrier gas. The magnitude of this increased response will depend upon the particular detector. The substitution of nitrogen for helium carrier gas will also improve resolution within the GC column. The more dense the carrier gas the better the resolution.

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9.6 If the number of flame ionization detectors being fed the output from the pure air generator with “B” reactor is insufficient to produce a flow of at least 50% of the rated output volume, it is advisable to incorporate a “tee” bleed valve to achieve this flow.

9.7 When operating any pure air generator that has a “B” reactor, mixer-receivers

must be incorporated in the system. Their purpose is to homogenize the oxygen/nitrogen effluent developed by the “B” reactor. It is imperative that no other chambers are used for this purpose and that these chambers remain empty.

9.8 The “B” purification reactor should not be used to produce air that is to serve as

diluent in the production of air blends, standards, etc., for air monitoring equipment. Nor should it be used for instrumentation where air is used as the carrier gas or support air, as with total hydrocarbon analyzers. The hyper oxygenation will cause difficulties with calibration and the increased response will appear as hydrocarbon response though the air is hydrocarbon-free. The “A” or “C” purification reactors should be used for these applications.

9.9 The “C” PURIFICATION REACTOR is identical with the “A” unit except that the

carbon dioxide concentration will be less than 0.3-ppm, see Figures 12 and 13. This reactor is mandatory in those situations where carbon dioxide is actually being measured; e.g., nondispersive infrared where all hydrocarbons and carbon monoxide are oxidized to carbon dioxide before measurement, the moving wire liquid chromatograph whereby all carbon dioxide is converted to methane and measured with flame ionization detection, and those TOC systems employing the technique. For those situations where the carbon dioxide serves as an interferant for the analysis of other components, such as carbon monoxide, the “C” purification reactor must be used. This is the preferred reactor for FTIR applications.

9.10 The “D” PURIFICATION REACTOR is for those applications requiring high

purity and extremely low moisture. It has the same performance specifications as the other three reactors but has a moisture content of less than 1-ppm. Ionmobility analyzers and plasma chromatographs require this purification reactor. Other applications include air supplies for automatic samplers, valves, and pneumatic systems. The low moisture content eliminates maintenance problems with these systems.

9.11 For those instances were pure air with high humidity is required, AADCO

Instruments will supply a humidifier to be located after the pure air generator. This device will operate under pressure and produce air with 50-90+% RH. This addition alleviates the drying problem associated with the premapure dryer used in some air monitoring instrumentation.

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10.0 METHANE REACTORS. 10.1 The methane reactors are canisters, Figures 6, 7, 8 and 8a (20), containing a

low temperature catalyst, a heating system, and a temperature controller. The system temperature is factory set at the optimum temperature for the destruction of methane (about 290oC ± 10 oC). A cooling coil Figures 6, 7, 8 and 8a (27) is placed between the methane reactor and the exit fitting labeled PURE AIR so that the temperature of the effluent hydrocarbon free air does not

exceed 40C. 10.2 This reactor, when installed in any 737-series pure air generator, is electrically

controlled by the POWER switch, Figures 3 and 4 (2), on the face of the generator unit. The equilibration time from initial power is about sixty minutes. IT IS ADVISED THAT NO INSTRUMENTATION BE CONNECTED TO THE PURE AIR GENERATOR DURING THIS INTERVAL SINCE COPIOUS AMOUNTS OF WATER ARE DRIVEN FROM THE CATALYST DURING THIS PERIOD, See Figure 14.

10.3 During this initial “burn-in” a low flow of air should be permitted to pass through

the methane reactor to sweep the accumulated water from the reactor and effluent tubing prior to connection to the using the equipment. A rotameter reading of about 1/4 scale, set with the OUTPUT FLOW ADJUST, Figures 3 and 4 (13), and about 20-psig output pressure, set with the OUTPUT PRESSURE REGULATOR, Figures 3 and 4 (5), should be adequate.

10.4 The methane reactor will accommodate hydrocarbons, methane, and carbon

monoxide concentrations in air to 500-ppm. Most ambient levels are below 5-ppm. The life span of the catalyst is almost indefinite though rapidly poisoned by halogenated and sulfur compounds. It is for this reason that the methane reactor is always located after the purification reactor. The efficiency of the methane reactor for methane is expressed by the nomograph in Figure 16.

10.5 The methane reactor is recommended for the generation of air that is to be

hydrocarbon and carbon monoxide free. It is widely used in determining ambient methane levels, reactive versus non-reactive hydrocarbons, as source air for CO, CH4, and THC analyzers, preparation of air blends, combustion air for TOC analyzers, etc. A pure air generator with a “C” purification reactor is usually employed with the methane reactor for these applications. See Section 9.9

10.6 To remove the low level CO2 formed during the catalytic reaction, AADCO

Instruments offers an in-line, see through, CO2-indicating scrubber (part no. 737-120). This device is offered for those users who may be concerned with this low level CO2 and have a genuine need for air that is completely CO2 free.

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10.7 AADCO Instruments offers free standing methane reactors (Models 153 and 154) for those individuals who wish to remove hydrocarbons and carbon monoxide from their own oxygen or air sources. It should be borne in mind that suitable halogen and sulfur scrubbers are required if these compounds are present, when using these free standing units. The Models 153 and 154 are also ideal for destroying the ethylene used as excitation gas for chemiluminescent ozone analyzers rather than venting the ethylene within the monitoring vehicle.

10.8 The temperature of the methane reactor is monitored by the panel mounted

pyrometer, Figures 3 and 4 (7). Confirmation that the unit is operating at a controlled temperature is made by observing the METHANE HEAT lamp, Figures 3 and 4 (4) which will cycle when at operating temperature. Should the

pyrometer indicate a temperature other than 290C ± 10C, refer to Section 13.21 for remedial action.

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11.0 PERFORMANCE SPECIFICATIONS 11.1 The AADCO 737-series pure air generators produce air with less than 0.005-

ppm hydrocarbons, carbon dioxide, methane, ozone, sulfur dioxide, hydrogen sulfide, ammonia, and oxides of nitrogen. Carbon dioxide level is either at ambient level (~350-ppm) or less than 0.3-ppm, depending upon the model

purification reactor selected. Dewpoint is at least -60F; i.e., 20-ppm. See Section 9.0 Purification Reactors.

11.2 Oxygen concentration of the output air is about 20.8% for the “A”, “C”, and “D”

purification reactors and 37.0% ± 0.5% for the “B” units. These respective

oxygen concentrations are determined at -60F dewpoint and after the units have been in operation for at least four hours.

11.3 Source air may be from the oil-less compressor normally supplied with the

instrument, suitably filtered “house” air, “plant” air, or any other source, including cylinders.

11.4 Hydrocarbon content of the unclean input air may be as great as 500-ppm and

the methane concentration to a maximum of 0.2-ppm. For those sources containing greater than 0.2-ppm methane, methane reactors are required. These accessory units mount within the cabinets of all models and completely remove all hydrocarbons, carbon monoxide, and methane by converting these compounds to carbon dioxide and water. They are low temperature catalytic oxidizers that, when properly installed, have effluent temperatures no greater

than 40C. See Section 10.0 for details. 11.5 Output pressure is maintained constant within 0.05-psig through the maximum

output pressure range of each instrument without the use of ballast tanks. 11.6 All 737-series pure air generators are calibrated for purity before shipment.

They are standardized for output purity and oxygen concentration against a factory standard to assure consistent performance among all pure air generators. This standardization is performed at an input pressure and output flow commensurate with the rated output flow of the generator being tested. To reproduce this output purity, the generator must not exceed the maximum permissible output flow for that unit and must have the proper input pressure and flow for same. All compressors supplied with the 737-series pure air generators will meet or exceed the pressure and flow requirements for the respective units.

11.7 Factory conditions for each model are as follows:

737-11 - 20-LPM output flow @ 80-psig input pressure 737-12 - 30-LPM output flow @ 80-psig input pressure

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11.8 Any output flow greater than the stated maximum output flow for any particular model pure air generator produces air with purity worse than specifications. Nomographs, Figures 21 and 22, indicates output flow versus rotameter reading at STP.

11.9 The operator must realize that once other equipment is connected to the pure

air generator and output flow is controlled at the other equipment, the rotameter will then be pressurized and will indicate less flow than is actually being delivered. See Section 4.4.

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12.0 PREVENTIVE MAINTENANCE. 12.1 BALLAST BLEED - All accumulated water must be bled from the ballast tank

at least one every three days during continuous operation. This is done by operating the manual toggle valve or the momentary contact switch, Figures 3 and 4 (12), on the face of the pure air generator. There should be a firm flow of air from the BALLAST BLEED port, Figures 3 and 4 (11), usually accompanied by water that can be caught in a suitable container and discarded. The tank should be drained completely. During periods of high humidity the ballast tank should be bled every day.

12.2 BLEED SYSTEM. A weekly routine check should be made for plugging of the

bleed system. In all cases, whether manual or electrical systems, when the bleed valve is opened there should be a strong flow of air from the BALLAST BLEED port. If the air flow is weak or no water is emitted, there is a possibility that there is some blockage within the ¼-inch copper tubing leading to the bottom of the tank, the solenoid valve, or the _-inch plastic tubing leading to the front panel. This restriction should be cleared. Care should also be taken to be certain that the ballast bleed solenoid valve, Figure 9 (35), is operating, if that system is in the generator. Depressing the momentary contact switch should produce an audible “click” of the valve as well as a firm air flow from the BALLAST BLEED port.

12.3 FILTERS - All filters should be cleaned and replaced once per month if the

compressor operates continuously. The filters are: (1) The two inlet filters on the compressor, Figure 11 (44); and (2) the in-line filter located in the air line between the compressor and the generator units, Figure 1 (50).

12.4 METHANE REACTOR - A one or two minute observation of the METHANE

HEAT lamp, Figures 3 and 4 (4), should reveal cycling of the lamp. This gives positive indication of heat control to the methane reactor. A glance at the

pyrometer will also reveal that the unit is at temperature (290C ± 10C). If either check reveals some problem, see Section 13.21 for remedial action.

12.5 COMPRESSOR - A check of the INPUT PRESSURE gauge, Figures 3 and 4

(3), over a one or two minute period should reveal: (a) the compressor is operating properly (reaches a maximum pressure of about 80-psig and cuts OFF), and (b) the pressure switch/compressor pressure relief system is operating properly (cycles between 60-psig and 80-psig over a one minute period). If not, see Section 14.0 for remedial action.

12.6 PURIFICATION REACTOR - A one or two minute observation of the rotameter,

Figures 3 and 4 (10), should show the rotameter ball as remaining constant. If both the rotameter ball and the OUTPUT PRESSURE gauge, Figures 3, 4 and 6 (6), show sudden drops during a one minute cycle, see Section 13.8 for cause and remedy.

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13.0 TROUBLE SHOOTING 13.1 COMPRESSOR (See Section 7.0). 13.2 Depress the PUMP switch. The PUMP switch lamp should light and the

compressor should start.

(a) PUMP switch lamp lights but compressor does not start. Check INPUT PRESSURE gauge. If reading is 60-psig or greater, compressor cannot start. Depress POWER switch, so that air will drain from ballast tank and compressor will start when input pressure falls to 60-psig or less.

(1) Input pressure is less than 60-psig and compressor will not start.

Fuse is okay since PUMP switch lights. Problem lies with the pressure switch, the solid state relay, or the compressor.

NOTE: POWER IS ALWAYS PRESENT AT TERMINAL #1 OF AC

RELAY EVEN WHEN PUMP SWITCH IS OFF. TO AVOID SHOCK, EXERCISE CARE WHEN WORKING IN THE AREA OR WHEN CHANGING THE RELAY. FOR SAFETY, DISCONNECT POWER TO UNIT.

(2) Check voltage between terminal #4 on solid state relay and neutral

on terminal strip TS-1. Voltage not present indicates problem is with pressure switch. Confirm by removing pressure switch cover and shunting between two outside terminals. Voltage should appear at terminal #4 on solid state relay and compressor should start. If so, replace or reset pressure switch as in Section 14.0.

(3) Voltage is present at terminal #4 on solid state relay but compressor

does not start. Jump between terminals #1 and #2 on solid state relay. If compressor starts, relay is defective and must be replaced.

(4) Compressor does not start after jumping between terminals #1 and

#2 on solid state relay. Problem lies with compressor assembly. 13.3 The compressor has been in operation but has stopped suddenly. The unit

passes all tests as in Section 13.2 (a) (1) through (4). Problem must lie with cooling fan or compressor itself.

(a) Place hand under silencer housing and feel for exhaust air from cooling

fan when PUMP switch is ON. If this exhaust air is not felt, remove cover from silencer housing and observe fan rotation. If the fan is not running, replace fan.

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13.3 (a) Continued.

NOTE: There is an inaccessible thermal switch located within the body of the compressor motor which will cause the compressor to shut down should it begin to overheat. The compressor should begin operating within fifteen minutes after removing the cover from the compressor unit. This allows the compressor to cool without cooling fans.

(b) If the compressor has stopped due to overheating, a visual check should

be made of the plastic louvered shroud, Figure 11, on the front of the compressor to confirm that it has not become distorted due to overheating. PERFORM THIS INSPECTION WITH POWER CORD DISCONNECTED IN THE EVENT COMPRESSOR COOLS ENOUGH TO START. If it is distorted, remove the shroud by loosening the four screws holding it in place and check that the four blade fan inside has not been damaged due to the distortion. Replace one or both, if needed. See Section 16.0, Parts List.

(c) If the fan is not defective and the compressor has not overheated but will

not start, replace compressor. 13.4 Depressing the PUMP switch, as in Section 13.2, the PUMP switch lamp does

not light. Depress POWER switch confirming that power is present because if power is present POWER switch lamp should light as well as the METHANE HEAT lamp, and the cooling fan should operate. If not, circuit breaker is out and there is no power to unit. Restore breaker. If breaker okay, check power cord connections.

(a) Check PUMP fuse. PUMP fuse blown. REMOVE POWER CORD FROM

WALL OUTLET BEFORE CHECKING OR CHANGING FUSES. Replace fuse with 30-amp SLOBLO. (Use 15-amp if 220V operation.) Must be SLOBLO. Compressor should start.

NOTE: The PUMP fuse will blow if the compressor starting current becomes

abnormally high. This will be due to: (a) the compressor having to start against pressure, See (1) below, (b) the compressor getting too warm because the cooling fans in the silencer housing have quit. See Section 13.3 (a), or (c) a short in the compressor itself, see (2) below.

(1) The compressor pressure relief valve is installed in every unit to

avoid having the compressor start against any pressure. To confirm that the compressor pressure relief valve is functioning properly: when the compressor is running, the ballast tank will fill to 80-psig and the compressor will turn OFF. At that instant when the compressor turns OFF, there should be a sudden expulsion of air from the compressor pressure relief valve, Figures. This represents a bleeding of air from the connecting tubing by this valve so that on compressor restart this

27

13.4 (a) (1) Continued.

tubing will be at ambient pressure. This insures no increase in starting current. If there is no expulsion of air from the compressor pressure relief valve when the compressor is OFF, replace the compressor pressure relief valve.

In addition, if this air expulsion continues for more than a few seconds the check valve, Figures 6, 7 and 9 (24), is probably defective. To confirm, depress the POWER switch to the OFF position. The input pressure as shown on the INPUT PRESSURE gauge should remain at that pressure which was evident the moment the POWER switch was depressed. If the input pressure continues to decrease, replace the check valve.

Further confirmation that the check valve is defective: with some pressure in the ballast tank, turn the POWER switch OFF and disconnect the metal tubing at the check valve, connect a short piece of plastic tubing to the check valve and immerse the free end in a cup of water. If air bubbles are present, replace the check valve. No air should be released from the tank.

(2) To determine if there is a short in the compressor, REMOVE THE

POWER CORD FROM THE WALL OUTLET and disconnect the black lead at terminal #2 of solid state relay. If the PUMP fuse blows when this lead is connected and does not blow when disconnected, replace the compressor. BE CERTAIN TO REMOVE THE POWER CORD FROM THE WALL OUTLET WHEN CHECKING OR CHANGING FUSES.

13.5 If a routine check, as in Section 12.5, reveals that the compressor does not

reach 80-psig within thirty seconds, starting at 60-psig, as observed on the INPUT PRESSURE gauge, with the POWER switch ON and the generator unit operating, then the compressor should be replaced. It is mandatory that this input pressure be available to the purification reactor for proper operation.

(a) A further check can be made by turning OFF the POWER switch and

allowing the compressor to fill the ballast tank until the input pressure reaches 80-psig and the pressure switch cuts off power to the compressor. This should occur within thirty seconds if the starting input pressure were at 60-psig and within two minutes if at zero. See Section 14.0 for proper adjustment of this setting if not at 80-psig and 60-psig.

(b) While performing tests in (a) above, it is a good time to check for any

leaks which may have developed between the compressor and the input to the purification reactor by checking all of the fittings between them with soap solution WHILE THE COMPRESSOR IS RUNNING and the lines are under

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13.5 (b) Continued.

pressure. This includes all connections on the ballast tank, the compressor hoses, and the tubing leading to the INPUT PRESSURE gauge, as well as the tubing leading to the input of the purification reactor. Any leaks will make it appear as though the compressor is not operating to capacity.

(c) A check should be made of the compressor pop-off valve, Figure 11 (48).

Air should not be coming from the valve when the input pressure is below 100-psig. If there is, the valve should be adjusted to eliminate the leakage. Use a _-inch wrench to loosen the locknut at the end of the pop-off valve and a ½-inch wrench to turn the adjustment nut clockwise to increase the pop-off pressure setting. Once the air leakage has been stopped, tighten the _-inch locknut while holding the ½-inch adjustment nut securely to avoid changing its setting. Should it be impossible to stop the leak, replace the pop-off valve with one which has been pre-set. See Section 18, Parts List.

13.6 If the compressor continues to run after the input pressure reaches 80-psig and

the input pressure continues to rise beyond 80-psig, the problem lies with the solid state relay or the pressure switch.

(a) Depress the PUMP switch to OFF position. If compressor continues to

run, replace solid state relay.

(b) If voltage present at terminal #4 of solid state relay even when input pressure is above 80-psig, the pressure switch is defective. Make adjustments to switch as in Section 14.0 or replace with new pre-set pressure switch, making connections as on defective pressure switch.

13.7 If compressor continues to run after the PUMP switch is depressed to the OFF

position:

(a) Check voltage between position #2 and position #4 of terminal strip TS-1, located on the front floor of generator unit (see Figure 18). When PUMP switch is OFF, there should be no voltage. If voltage is present, PUMP switch is defective. Replace the pump switch.

(b) If no voltage is present in (a) above, check voltage between terminal #2 of

AC solid state relay to neutral of terminal strip TS-1. If voltage is present, relay is defective. Replace the relay.

13.8 PURIFICATION REACTOR. 13.9 If, as in Section 12.6, a one or two minute check of the rotameter reading,

Figures 3, 4 and 6 (10), as well as the OUTPUT PRESSURE gauge, Figures 3, 4 and 6 (6), should both show sudden drops during a one minute observation.

29

30

13.10 If the sudden change is only momentary with recovery within a second or two it would indicate that the output pressure has been set too close to the low pressure setting of the pressure switch. For the OUTPUT PRESSURE REGULATOR, Figure 4 (5), to operate effectively, a pressure differential of at least 10-psig must be maintained between these two pressure settings with the low pressure setting of the pressure switch being the higher of the two. Since the recommended low pressure setting of the pressure switch is 60-psig, the maximum permissible output pressure, as set with the OUTPUT PRESSURE REGULATOR, is 50-psig in order to maintain the 10-psig differential. If either of the above pressure settings do not conform to this restriction, make the necessary pressure adjustments beginning with the low pressure setting of the pressure switch. See Section 14.0.

13.11 A further confirmation of this condition can be made by monitoring the purge

flow. It should be noted that during some portion of each one minute cycle, for an interval of about four seconds, there is no purge flow. This period occurs when either S-1 or S-2 is activated and, during the same interval, the alternate valve is energized. Should it be that S-1 is activated, then column one would be pressurized. The moment S-2 is energized there is a sudden demand for pressurized air from the ballast tank to fill column two. The ballast tank at the time may only be at 60-psig, the lower pressure setting of the pressure switch. If, during this interval, the OUTPUT PRESSURE REGULATOR were set between 52 and 60-psig the symptoms described in Section 13.9 will prevail. By observing the four second purge stop-flow interval and glancing at the OUTPUT PRESSURE gauge, one would notice a sudden, sharp decrease in output pressure simultaneously. This would serve to confirm the problem as outlined in Section 13.9.

13.12 If for only one-half of each one minute cycle there is full output pressure as

observed on the OUTPUT PRESSURE gauge; full pure air flow, as observed on the OUTPUT FLOW rotameter; or there is full purge flow; these symptoms indicate only one of the solenoid valves on the inlet to the purification reactor is being energized during the full one minute cycle or that flow through one of the solenoids is being obstructed.

13.13 During the second half of the one minute cycle described in Section 13.11,

there will be little or no output flow, as observed on the OUTPUT FLOW rotameter, and little or no output pressure as seen on the OUTPUT PRESSURE gauge. This further confirms that only one of the solenoid valves on the inlet to the purification reactor is being energized during the full one-minute cycle or that, for some reason, flow through one of the solenoid valves is being obstructed.

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13.14 For further confirmation, it is necessary to access the electrical system, timers, etc. Remove the cover from the generator unit and remove the ballast tank. To do so:

(a) DISCONNECT THE POWER CORD AT THE REAR OF THE UNIT.

(b) Disconnect the _-inch tubing leading to the BALLAST BLEED fitting on the

front panel, at the front panel.

(c) Disconnect the _-inch tubing leading to the INPUT PRESSURE gauge, at the gauge.

(d) Disconnect the ¼-inch copper tubing connecting the inside pump fitting to

the check valve, Figures 6 and 9 (24), on the ballast tank.

(e) Disconnect the ¼-inch plastic tubing leading to the inlet of the purification reactor from the ballast tank, at the ballast tank.

(f) Disconnect the electrical quick-connect between the pressure switch and

main electrical harness.

(g) Disconnect electrical quick-connect, if present, between the ballast bleed timers and ballast bleed valve located on top of the ballast bleed tank.

(h) Remove the two hex bolts, located on the underside of the generator unit,

which hold the ballast tank in place.

(i) Remove the ballast tank, taking care not to damage any solid state timer wiring located at the rear foot of the ballast tank.

13.15 Reconnect the power cord and, with the POWER switch ON, observe whether

the timer, Figure 8 (41), is fully operational, partially operational, or not operational.

(a) Listen for the “click” of the solenoid valves, during one full minute cycle of

the timer. Each should be energized for alternate halves of each cycle. If both solenoids “click”, the problem is an obstruction in one or the other solenoid valves on the purification reactor. If the purification reactor is older than one year, replacing both of the solenoid valves is best. If the purification reactor is less than one year old, contact the factory for a complete purification reactor replacement under warranty.

NOTE: AADCO Instruments offers a purification reactor complete with all

valves, fittings, etc., for a discounted price with trade-in of the depleted reactor.

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13.15 Continued.

(b) If the solenoid valves do not “click”, disconnect the electrical quick-connects leading from the timer to the purification reactor valve. Measure the AC voltage at each quick-connect leading from the timer. The voltage should be 120V or 220V, depending upon the power source, during alternate halves of the timer cycle.

(1) If DC voltage not present, disconnect the electrical quick-connects

leading from the timer to the transformers. Measure the AC voltage at each quick-connect leading from the timer during alternate halves of timer cycle.

(2) If AC voltage not present at either quick-connect, check AC voltage on

input side of timer. If not present, check AC output of RFI filter. If not present, replace filter.

(3) If AC voltage present at one quick-connect but not at the other, the

problem lies with the timer. Replace timer.

(4) If DC voltage present at the quick-connect leading from the transformers, measure the resistance of each solenoid coil at the quick-connect leading to the solenoid valve. It should be about 175-ohms. If other than this, coil is either open or shorted and the solenoid valve should be replaced.

(c) Check the AC voltage going to and from RFI filter. If voltage going in but

not coming out, replace RFI filter. If both voltages present, then timer is defective. Replace timer.

13.16 If there is purge flow although the POWER switch is OFF (no power to the solenoid valves or purification reactor), the problem lies with one of the purification reactor’s solenoid valves experiencing “blow by”. It is due to the weakening of the spring within the coil housing. This spring holds the spindle against its seat when the coil is not energized, effectively closing the inlet side of the valve at any pressure up to 100-psig. If the spring is defective, air is admitted through the purge valve and opposite column system rather than through the check valve, pressure regulator, etc., this air appears as purge air through the opposite solenoid valve.

NOTE: BECAUSE OF THE 100-PSIG LIMITATION FOR THE INPUT AIR

PRESSURE, IT IS IMPERATIVE THAT THE PRESSURE SWITCH SETTING NOT EXCEED 100-PSIG. EXCEEDING THE 100-PSIG INPUT PRESSURE WILL CAUSE IMPROPER OPERATION OF THE PURIFICATION REACTOR AND, THEREFORE, PRODUCTION OF IMPURE AIR.

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13.17 Further confirmation of this condition can be made by removing the connecting tubing from the tops of the solenoid valves; i.e., the common dump connection; and determining which solenoid valve is leaking when its coil is not energized by feeling the flow from the top of the valve with the POWER switch OFF and pressurized air being applied to the solenoid valve inlets. The defective solenoid valve is that valve which does not evidence purge flow since its opposite number is leaking when non energized. Replace solenoid valves.

13.18 If the purge flow is constant (never having no-flow conditions as described in

Section 13.9) or appears to be extremely unequal from one side of the purification reactor to the other during normal operation with the POWER switch ON, the cause is a defective check valve on the output side of the purification reactor. To determine which check valve is defective, disconnect a quick-connect leading to one solenoid valve on the input to the purification reactor with the POWER switch ON and pressurized air at the valve inlets. If the purge air is normal, the defective check valve is on the same half of the purification reactor as the solenoid valve receiving power. If the purge air is abnormally high, the defective check valve is on the opposite half of the purification reactor. Replace the defective check valve.

13.19 Further confirmation can be made that one check valve is defective by: (a)

turning the POWER switch OFF, (b) remove the ¼-inch tubing, connecting the output of the purification reactor to the input of the output pressure regulator, (c) connect pressurized air to the output fitting of the purification reactor, (d) there will be a high flow of air from the top of that solenoid valve which is in the same half of the purification reactor which has the defective check valve.

NOTE: It may be necessary to remove the ¼-inch tubing joining the purge

connections of the two solenoid valves to isolate that valve which is producing the improper purge flow.

13.20 Should the cooling fan, Figures 6, 8, 8 and 8a (28), fail, the generator cabinet

will feel unduly warm and the pure air that exits from the PURE AIR fitting on the rear of the unit will feel warm also, since the cooling fan passes air over the cooling coil, Figures 6, 7 8 and 8a (27). To confirm that the cooling fan has failed, place a hand behind the screened opening on the rear of the generator unit. If no air flow is evident when the POWER switch is ON, replace the fan. It is held in place by four 6-32 screws with kep-nuts. The electrical connection is via electrical quick-connect. Be certain that the replacement fan is oriented properly to blow air to the outside of the cabinet.

13.21 THE METHANE REACTOR 13.22 When the POWER switch is depressed, power is applied to the methane

reactor. The METHANE HEAT lamp, Figure 4 (4), should light and within a few minutes there should be an upscale deflection of the pyrometer, Figure 4 (7).

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13.22 Continued. (a) If the METHANE HEAT lamp does not light, wait several minutes to see if

there is an upscale deflection of the pyrometer. If there is, then the lamp is defective. Replace the lamp.

(b) If neither the METHANE HEAT lamp nor the POWER switch lights, check

the POWER fuse, Figure 4 (9). REMOVE THE POWER CORD FROM WALL OUTLET WHEN CHECKING OR REPLACING FUSES. If the fuse is okay but the pyrometer indicates a temperature rise after a few minutes, though both lamps are not lighted, replace both lamps.

(c) If the fuse is blown in (b), remove the cover of the generator unit.

DISCONNECT THE MAIN POWER CORD FROM THE WALL OUTLET, and the quick-connect leading to the methane reactor, Figures 6, 7 8 and 8a (20). Install new fuses and reconnect power cord.

(d) If the fuse blows when POWER switch is ON, disconnect the power cord

at the cooling fan, Figures 6, 7, 8 and 8a (28). REMOVE POWER CORD FROM WALL OUTLET and replace fuse. Reconnect power cord and depress POWER switch to ON position. If the fuse blows, the POWER switch is defective and must be replaced. If the fuse does not blow, the cooling fan is shorted. Replace fan.

13.23 If the fuse does not blow in (c) above, the problem is the methane reactor.

(a) Check resistance between chassis and white and black wires leading to the methane reactor. If resistance is infinite, methane reactor wiring okay. Replace fuse. REMOVE POWER CORD FROM WALL OUTLET WHEN CHECKING FUSES. Unit should operate properly.

(b) If resistance is zero, there is a short in the wiring inside the methane

reactor. Disconnect black, white and red leads of the methane reactor at the terminal strip. Measure resistance between red and black leads. This should read zero, showing continuity through the temperature controller. If resistance is infinite, replace the controller.

(c) Measure resistance between red and white leads. Resistance should be

about 50-ohms for 120V or 190-ohms for 220V operation. If resistance is zero or infinite, replace heater. If infinite resistance, the heater is open and will not heat nor blow the fuse. In addition, the METHANE HEAT lamp will remain on constantly. If zero resistance, indicating a short condition, the fuse will blow.

NOTE: AADCO Instruments, Inc. offers a rebuilt methane reactor for a

discounted cost with the trade-in of the depleted unit.

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13.24 If the pyrometer indicates a temperature other than 290C ± 10C and the METHANE HEAT lamp is cycling, the methane reactor is at proper operating temperature but either the pyrometer or the thermocouple is defective.

(a) Disconnect the thermocouple electrical disconnect between the methane

reactor and the pyrometer. Measure the DC voltage output of the thermocouple at the female disconnect leading to the methane reactor. It should read fairly close to the 14.0-MV if the unit is at operating temperature. If not, replace the thermocouple.

(b) If the pyrometer indicates a temperature other than 290C ± 10C and the thermocouple output is about 14.0-MV, replace the pyrometer.

13.27 Remote Compressor Operation (737-106). 13.28 With PUMP switch OFF and DC voltage applied to the DC input jacks the

compressor should start if:

(a) The auxiliary power cord is connected to the AUX POWER connections on the rear of the generator, Figure 5 (30) and the rear of the compressor unit, Figure 10 (36).

(b) The input pressure is below 60-psig as shown on the INPUT pressure

gauge Figures 3 and 4 (3). 13.29 Compressor does NOT start. Disconnect the DC voltage source and depress

PUMP switch. Compressor should start, indicating that the pressure switch and solid state AC relay are okay. Problem must lie with DC relay.

13.30 Depress PUMP switch to OFF and re-connect DC voltage source, observing

polarity when doing so. Confirm that the DC source voltage is present between positions #3 and #4 on the DC relay. Check voltage at position #1 and neutral. Should be the same as AC input, i.e., either 120V or 240V. If not present, check voltage at position #1 on the AC relay. If not present, fuse is blown. Replace PUMP fuse with 30-A 250V SLOBLO while power cord is disconnected from outlet.

13.31 Voltage present at position #1 on DC relay. Check voltage at position #4 on AC

relay. Should be same as AC source voltage. If not, replace DC relay. Note: this is a RANDOM on and not zero-crossing relay. See Section 16.0, Parts List.

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13.32 Auto Ballast Bleed (737-107) 13.33 Depress ballast bleed switch Figure 4 (12), while the compressor is operating

and the ballast tank is under pressure as viewed on the INPUT PRESSURE gauge, Figure 4 (3). Air and possibly water should exit from the bulkhead fitting, Figure 4 (11). If not, check all bleed tubing from bulkhead fitting, the bleed valve, and ballast tank tubing for plugging. Clean or replace tubing. Be certain to check that the valve is operating when the ballast bleed switch is depressed by holding the valve in your hand and sensing the opening and closing of the valve while operating the switch. Replace valve if defective. See Section 18, Parts List.

13.34 Auto Ballast Bleed timer function check. 13.35 After determining that the ballast bleed system is operating, as in 13.32 above,

depress PUMP switch to OFF, wait several seconds and turn PUMP switch ON. Notice the time of actuation and in approximately ten minutes the ballast bleed valve should open for 20-seconds disgorging air and water from the ballast tank. If not, replace the auto ballast bleed timer.

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14.0 PRESSURE SWITCH ADJUSTMENT 14.1 The pressure switch, Figures 6 and 9 (17), located on the ballast tank, controls

the pressure range for compressor operation. This range is usually between 60 and 80-psig.

14.2 The two opposing but adjacent white, knurled knobs (one considerably larger

than the other) are accessible without removing the dark plastic cover. These knobs determine upper and lower range settings. They are interactive adjustments; i.e., varying one will influence the setting of the other but not to a great degree. The larger knob controls the upper pressure setting and is continuously variable through ten to twelve full turns. The smaller knob is

variable only through 270 rotation. 14.3 The INPUT PRESSURE gauge is the operator’s pressure reference for the

adjustment procedure. 14.4 With the PUMP switch OFF and all pressure drained from the system by

allowing the POWER switch to remain ON, adjust the smaller, white knob on the pressure switch about midway of its travel. This is an arbitrary setting and later will be further adjusted.

14.5 Depress the PUMP switch ON and POWER switch OFF and observe that

pressure on the INPUT PRESSURE gauge at which the compressor cuts OFF. This should be about 80-psig. If not at 80-psig but at some lower pressure, rotate the larger knob clockwise so that the black ring on the knob moves to a higher pressure setting, as observed on the pressure scale of the switch (calibration marks 0-260 psig) and vice versa if too high.

14.6 Depress the POWER ON switch so that air is bled from the ballast tank by the

system and the input pressure will decrease. Make a note of that pressure at which the compressor cuts ON. This should be about 60-psig.

14.7 If the observed pressure in Section 14.5 were not 80-psig but some higher

pressure, rotate the larger knob so that the black ring on the knob moves toward a lower pressure reading on the switch pressure scale. As the input pressure increases, once again note that pressure at which the compressor cuts OFF. From the incremental decrease from the initial pressure reading and the amount that the larger knob was turned, a determination can be made as to how much, approximately, is required to make that setting for compressor cut-off at 80-psig.

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14.8 After completing the setting which controls the 80-psig compressor cut-off, observe the 60-psig reading. If too low, turn the small, white, knurled knob clockwise to increase its reading and counter-clockwise to decrease its setting. After each adjustment of the small, white, knurled knob, the larger knob must also be adjusted to maintain the 80-psig cut-off because of the interaction of the two knobs.

NOTE: Once the switch has responded to the pressure changes by turning

the compressor ON or OFF, it is necessary that the switch perform its opposite function before the effect of any setting change can be perceived. If the compressor has turned OFF, it is necessary that the pressure in the ballast tank decrease and the compressor cut ON again before the next OFF pressure reading will be relevant. Simply altering the high pressure setting at one end of the pressure range or the other while at that pressure, is impracticable.

14.9 It is possible to make fairly close pressure settings for both the 60-psig and 80-

psig settings by following the directions above. However, if unable to achieve the 20-psig range nor the 60 and 80-psig readings, replace the pressure switch with one which has been pre-set. See Section 16.0, Parts List.

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15.0 COMPONENT REPLACEMENT 15.1 TO REPLACE THE PURIFICATION REACTOR:

(a) REMOVE THE POWER CORD FROM THE WALL OUTLET and disconnect the two electrical disconnects leading to the solenoid valves of the purification reactor.

(b) Disconnect the ¼-inch plastic tubing leading from the ballast tank to the

inlet of the purification reactor, at the ballast tank.

(c) Disconnect and remove the ¼-inch tubing leading from the output of the purification reactor to the input of the OUTPUT PRESSURE REGULATOR, Figures 4, 6 and 8 (5).

(d) Remove the two 10-32 screws on the underside of the generator cabinet

which hold opposite corners of the purification reactor.

(e) Disconnect the ¼-inch tubing leading to the DUMP connection on the rear wall of the generator unit.

(f) Lift the defective purification reactor from the generator unit.

(g) Transfer the ¼-inch plastic tubing which is attached to the inlet side of the

reactor to the inlet side of the replacement purification reactor.

(h) Retrace steps (e) through (a). It is not necessary to make any flow adjustments with the new purification reactor since all adjustments will have been made at the factory. Be certain to leak check all connections.

15.2 TO REPLACE THE METHANE REACTOR:

(a) REMOVE THE POWER CORD FROM WALL OUTLET and disconnect the quick-connect leading from the terminal strip to the methane reactor and the two-conductor thermocouple quick-connect between the pyrometer and the methane reactor.

(b) Disconnect and remove the cooling coil.

(c) Disconnect the ¼-inch tubing leading from the output of the rotameter to

the inlet of the methane reactor.

(d) Remove the three 8-32 kep-nuts and one-inch washers from the underside of the generator cabinet which hold the methane reactor in place.

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(e) Remove the methane reactor from the cabinet and install the replacement, reversing steps (a) through (d).

15.3 TO REPLACE A DEFECTIVE PUMP OR POWER SWITCH:

(a) REMOVE THE POWER CORD FROM WALL OUTLET and remove the ballast tank as described in Section 13.13.

(b) Disconnect the blue and white leads for this switch at the terminal strip.

(c) Slide the shrink tubing covering the POWER or PUMP fuse back and

remove the black lead quick-connect from the fuseholder.

(d) Remove the four screws on the outside of the front panel which hold the rotameter in place, keeping the clear plastic rotameter viewing screen from falling down into the unit.

(e) Use a 9/16-inch wrench to loosen the nut behind the front panel which

holds the switch in place.

(f) Unscrew the black switch bezel which encircles the red cap while holding the switch with other hand. (Note: by loosening the rotameter and pushing it back away from the inside of the front wall of the generator, you have access to the nut that holds the switch in place.) The switch is now free to be removed.

(g) Before installing the new switch, be certain to transfer the nut and washer

in (e) above to the new switch before putting it through the switch hole. 15.4 TO REPLACE A PUMP OR POWER LAMP:

(a) Grasp the red lens cap and pull out of switch to expose the lamp.

(b) Remove the lamp and insert replacement by shoving into the switch until it snaps into place.

(c) Replace lens cap.

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16.0 PARTS LIST. 18.1 Before attempting to replace any part or component, be certain to read the blue

AADCO Instruments, Inc. label on the outside rear wall of your pure air generator to determine the model number and operating voltage requirements for proper parts selection.

Reference Part Number Number Description

16 20049 Ballast Tank 43 20051-2 Compressor, specify voltage 46 20052-1 Compressor Mounting Plate

20171 Compressor Mounting Guide Rod with Washers and Nuts, Set/4

20172 Compressor Guide Rod Grommet, Set/4 20173 Compressor Mounting Plate Grommet to attach Guide

Rod, Set/4 20164-1 Compressor Shock Mounts, Set/4 20174 Compressor Spring Guides, Set/4 20180 Compressor Support Spring, Set/4

28 20158 Fan, Generator, Specify Voltage 45 20161 Fan, Compressor Silent Housing, specify voltage

20159-1 Fan Screen 44 20165 Filter, Compressor Intake

20165-1 Filter Element, for Part No. 20165, 2/set 50 20166 Filter, Generator In-Line

20166-1 Filter Element, for Part No. 20166 20166-2 Filter, In-Line, large gasket for Part No. 20166 20166-3 Filter, In-Line, small gasket for Part No. 20166

40 20034 Filter, RFI 9 20010 Fuse Kit, Power and Pump (specify model generator) 47 20198 Hose, braided with fittings 4 20156 Lamp, Methane Heat Indicator 1,2 20150-1 Lamp, Power & Pump Switch 1,2 20150-2 Lens Cap, Power & Pump Switch 20 737-41 Methane Reactor, complete

20155-5 Methane Reactor Cartridge Heater, 300W, specify voltage

20155-1 Methane Reactor Heater Harness, specify voltage 20155-2 Methane Reactor Temperature Control Switch, pre-

set 60 737-36 Mixer-Receiver, with tubing and fittings 3,6 20141 Pressure Gauge, specify range 13 20033-1 Pressure Regulator, Output 18 737-23 Purification Reactor, 20-LPM, Specify A, B, C or D

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16.0 Continued.

Reference Part Number Number Description

18 737-24 Purification Reactor, 30-LPM, Specify A, B, C or D 7 20149 Pyrometer, pre-wired and calibrated 21 20169-1 Relay, solid state, AC, 40-AMP, specify voltage

20170 Relay, Solid state, DC, 10-AMP 10 20060 Rotameter, Specify generator output 43 20162-1 Shroud for Compressor Fan 1,2 20150 Switch, Power & Pump, Pre-wired

20149-2 Thermocouple, Pre-wired 41 20153-1 Timer, Solid State, Specify generator output 26 20191-1 Timer Combination, Total and Bleed Time, Single Unit

20192 Timer for 737-108, Bleed Time 20194 Timer for 737-108, 24 Hour

51 20154 Transformer with Rectifier, 33V DC 35 20182 Valve for 737-107 and 737-108, 2-Way, Ballast Bleed

20047-1 Valve, Compressor Pressure Relief, Mac 48 20048 Valve, Compressor Pop-Off, Preset 24 20046 Valve, Check, Ballast Tank Mount, Elbow 13 20065 Valve, Output Flow Control 39 20031-1 Valve, Solenoid, Purification Reactor Inlet 42 20184 Valve, Check, 1/8-inch Female Pipe, Purification

Reactor

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48

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51

52

53

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57

58

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60

61

62

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WARRANTY

Aadco Instruments, Inc. warrants instruments of its

manufacture to be free of defects in material and

workmanship for one year from date of shipment to the

purchaser. Its liability is limited to servicing or replacing any

defective part of any instrument returned to the factory by

the original purchaser. All service traceable to defects in

original material or workmanship is considered warranty

service and is performed free of charge. The expense of

warranty shipping charges to our factory will be the

customer’s responsibility. The expense of warranty shipping

charges to the customer will be borne by Aadco Instruments,

Inc. Service performed to rectify instrument malfunction

caused by abuse or neglect and service performed after the

one year warranty period will be charged to the customer at

the then current prices for labor, parts and transportation.

The right is reserved to make changes in construction,

design specifications, and prices without prior notice.